Orbital Composites, based in Campbell, California, has received a Tactical Funding Increase (TACFI) contract worth $1.9 million from SpaceWERX.
SpaceWERX is the innovation arm of the US Space Force that helps bring new commercial technologies into defense programs. The latest funding will support the company’s robotic additive manufacturing platform for extreme environment materials.
The company focuses on producing parts that can survive extremely harsh operating conditions. These components must handle temperatures above 3,000 degrees Celsius, repeated heating and cooling, and high-speed combustion gases. Such conditions are common in advanced military, aerospace, and energy systems.
Orbital uses robotic manufacturing, advanced materials, and physical artificial intelligence to automate much of the production process.
Physical AI combines software with robotics so machines can make decisions during manufacturing. This approach aims to reduce production time, improve consistency, and lower costs.
Traditional manufacturing of these materials typically takes 12 to 18 months. It also requires expensive production methods and specialized facilities. Orbital’s technology is designed to shorten these timelines and increase manufacturing capacity.
Why Extreme Environment Materials Matter
Extreme environment materials play an important role in several strategic industries. They are used in rocket nozzles, heat shields, hypersonic vehicles, jet engine hot sections, missile systems, and nuclear reactors. These components must continue working even under intense heat and pressure.
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Industry experts have highlighted that the US faces limited domestic production capacity for these advanced materials. Supply shortages have affected the availability of important defense and aerospace components. Faster manufacturing has become a priority as demand continues to grow.
Orbital says its manufacturing platform is designed to serve multiple industries through a single, scalable system. The same production technology can be adapted for defense, commercial space missions, and advanced energy projects. This flexibility allows manufacturers to produce different types of high-performance components using a common production process.
Space Force Backs Innovation
Chief Executive Officer Amolak Badesha said the project addresses one of the biggest barriers to scaling production of high-temperature rocket nozzles.
He said the company’s immediate goal is to remove supply constraints that have limited the production of solid rocket motors for military use. Badesha also said the program supports efforts to strengthen America’s manufacturing competitiveness in advanced materials.
AI-Driven Factories Support Space Programs
Orbital’s long-term vision extends beyond producing individual parts. The company wants to build AI-driven factories where digital designs move directly into automated production systems. This process aims to deliver finished components more quickly while reducing manufacturing costs.
Founder and Chief Technology Officer Cole Nielsen-Cole said current manufacturing methods remain too slow and expensive for many critical systems.
He said the company is working toward factories that can automatically produce mission-ready parts from digital design files. Such automation could significantly improve production speed for advanced defense and aerospace programs.
The company is already working with major defense contractors, US government agencies, and commercial customers. These partnerships focus on qualifying new manufacturing methods and increasing production capacity. Orbital is also investing in larger manufacturing facilities and AI-powered production technologies.
SpaceWERX plays a central role in helping startups develop technologies for the US Space Force. Working alongside the Commercial Space Office within Space Systems Command, the organization connects private industry with military needs. During fiscal year 2025, SpaceWERX awarded more than 300 contracts worth about $510 million.
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AFWERX, another innovation organization within the Department of the Air Force, also supports technology development for defense applications.
In fiscal year 2025, AFWERX awarded more than 1,000 contracts totaling approximately $1.37 billion. It also completed 438 Phase III transitions valued at more than $8.1 billion, helping move promising technologies into operational use.
Orbital Composites was founded in 2015 and continues to expand its work in advanced manufacturing. The company develops high-performance components, such as rocket nozzles and heat shields, through robotic additive manufacturing. It works closely with the US Space Force, the Air Force Research Laboratory, and leading defense contractors.
The new TACFI award represents another step in expanding domestic manufacturing for advanced materials that support national security, commercial space exploration, and next-generation energy systems.
